Container

ABSTRACT

A container includes a pallet base having a rectangular deck and support portions extending downward from an underside of the deck and a channel extending into an upper surface of the deck along edges of the deck. A sidewall defines a corrugated rectangular wall having four sides and setting into the channel in the pallet. Magnets are embedded into two sections of the sidewall to attract and retain the sections together. A cover fits over the sidewall. Alignment portions are formed in the channel and complementary alignment portions are formed in the bottom of the sidewall for aligning the sidewall with the pallet base. The pallet base includes intersecting strap receiving portions formed in an underside of the pallet base and the cover includes intersecting strap receiving portions formed on a top portion of the cover. The sidewall may be a see through material to provide for viewing contents from outside the container. The sidewall has two elements joined together along complementary vertical edge elements with recessed magnets pulling the edges together.

PRIORITY

This application claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/239,339 filed Sep. 2, 2009, and U.S. Provisional Patent Application Ser. No. 61,152,681, filed Feb. 13, 2009.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates to a container system having separable elements, and in particular to a lightweight, stackable, high strength container system that utilizes a pallet as a base for the container, a corrugated sidewall and a cover fitting over the sidewall.

2. Description of the Prior Art

Containers for shipping dense, heavy materials are well known. In order to accommodate and adequately retain and support the materials, the walls of the container must be sufficiently strong. Such containers tend to be made of thick, heavy materials that detract from their utility due to difficulty in handling the heavy containers even when empty. Moreover, it is advantageous to have containers that may be broken down and separated into a cover, base and sidewall elements. The utility of the containers further improves as such elements may be stacked when not in use. Such containers further require access by a forklift or pallet jack tines for greater utility.

Efforts to achieve lightweight, high strength shipping containers such as used for shipping paper or other heavy materials led to the use of corrugated plastic construction materials. These materials generally provide a high strength lightweight structure. However, such materials may not have sufficient strength to be used for the sidewall of the container. Moreover, although such materials may have improved strength, these benefits may be outweighed by difficulties when handling and retaining heavy articles. In addition, even if reinforced, further problems may exist with regard to aligning the container base and cover with the sidewall.

Straps or bands may be wrapped over the cover and under the base when assembled to retain the container components against one another and maintain the components in proper alignment. As the assembled containers are often moved with forklifts and pallet jacks, problems are encountered with tines dislodging the bands under the base or damaging the bands.

Sidewalls that form a somewhat rectangular periphery are often formed of two elements. Joining the two elements along their vertical edges presents challenges. Connecting devices placed on the planar surfaces of the sidewall may be damaged and/or may become disconnected so that the sidewall portions may separate. More robust connectors may add to the weight and complexity of the container.

It can be seen then that a new and improved container system is needed that can utilize lightweight construction while having sufficient strength to contain and support dense, heavy articles. Moreover, such a container should provide for alignment of the cover, base and sidewall elements. A container should also provide for retaining the sidewall, base and cover by banding the elements together longitudinally and laterally and resisting dislodging of retainer bands. The present application addresses these problems, as well as others associated with containers.

SUMMARY OF THE INVENTION

The present invention is directed to a container system and in particular to a container system that is easily assembled and disassembled and is capable of containing and moving heavy loads. The container generally includes a cover, sidewall and base. The base is configured as a pallet that may be easily handled by forklifts and pallet jacks. Banding straps extend around the outer sides of the container and underneath the pallet and over the cover. The straps extend in both longitudinal and lateral directions to keep the components together and maintain their alignment.

The container cover is a molded plastic member that includes an outer lip and a channel configured for receiving an upper edge of the sidewall of the container. The cover also includes recessed sections along edges of the top that are aligned with and configured for receiving the bottom of the legs of another pallet when stacked above the container on the cover. The upper surface of the cover also includes laterally extending recesses and longitudinally extending recesses that are configured for receiving and retaining the bands or straps wrapped around the container to retain the elements together.

The sidewall is a generally rectangular structure with four generally vertically extending faces. The sidewall may be configured in two sections that are joined together along vertical edges with magnets and extruded aluminum vertical edge elements. The corners of the sidewall structure may include a short angled section that provides a transition between the edges of the planar rectangular sidewall portions. The sidewall is generally configured of a high strength corrugated plastic material with flutes that receive reinforcing rods at key positions. The sidewall may have a double wall construction and may include an outer wall layer with flutes extending in a transverse direction to the flutes and reinforcing rods of the inner wall. A notch may be formed near the corner portions to extend over a raised reinforcing portion of the pallet and provide for alignment. In one embodiment the vertical edge elements have recessed formed therein for receiving complementary shaped magnets.

The pallet is a generally plastic molded pallet with a planar rectangular deck and legs extending from an underside of the deck. The legs are spaced apart and configured for receiving tines of a forklift or pallet jack. The legs also are aligned with the recesses in the cover for stacking and alignment.

The deck may include a non-skid surface and has a lip extending around the deck with a channel formed just inside the lip configured for receiving the bottom edge of the sidewall. Near each corner is a raised portion that is configured for extending into the lower notch in the sidewall. In addition, a reinforcing member extends through the raised portion to provide for reinforcement extending the entire length of the pallet.

The underside of the pallet deck includes reinforcing dimples and molded handle portions. Moreover, the underside of the deck includes recesses extending the length and width of the pallet and aligned with the recesses in the cover. The recesses receive the longitudinally and laterally extending retaining bands. Near each edge of the deck, corner portions provide for a smooth transition and alignment of the bands. The recesses are configured so that the lower edge of the deck extends down further than the bands when assembled so that the bands are maintained at a position so that they cannot be dislodged or damaged due to insertion of tines from pallet jacks or forklifts.

The container is easily assembled by inserting the lower edge of the sidewall into the channel in the upper surface of the pallet and having the cover placed over the sidewall with the upper edge of the sidewall extending in the corresponding channel formed in the lower surface of the cover. The retaining bands or straps are then wrapped around the container over both sides and over both ends to retain the elements together in an aligned and tight configuration.

In some applications, such as for storing currency, it is advantageous to be able to view the contents of the container. In one embodiment, the sidewall is made of a material that provides for viewing the container contents from outside of the sidewall. In one embodiment, the sidewall is a transparent or translucent corrugated polycarbonate. Such clear sidewalls provide for a quick visual inspection of the contents without disassembling the container.

These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views:

FIG. 1 is a perspective view of a container according to the principles of the present invention;

FIG. 2 is an exploded perspective view of the container shown in FIG. 1;

FIG. 3 is a top perspective view of a cover for the container shown in FIG. 1;

FIG. 4 is a bottom perspective view of the cover shown in FIG. 3;

FIG. 5 is a perspective view of a sidewall for the container shown in FIG. 1;

FIG. 6 is a top plan view of the sidewall shown in FIG. 5;

FIG. 7 is a detail view of flutes and reinforcing members for the sidewall shown in FIG. 5;

FIG. 8 is a detailed perspective view of the sidewall shown in FIG. 5 showing a bottom notch;

FIG. 9 is a top plan view of a second embodiment of a sidewall for the container shown in FIG. 1 and having double wall construction;

FIG. 10 is a top perspective view of a pallet base for the container shown in FIG. 1;

FIG. 11 is a bottom perspective view of the pallet base shown in FIG. 10; and

FIG. 12 is a detailed perspective view of the pallet base shown in FIG. 10 showing a protrusion in a channel formed in the upper surface of the pallet base;

FIG. 13 is a sectional view taken through the protrusion of the pallet shown in FIG. 10;

FIG. 14 is a sectional detail view of a reinforcing member in the protrusion shown in FIG. 13;

FIG. 15 is a sectional view taken from a side perpendicular to the view shown in FIG. 13;

FIG. 16 is a partially exploded view of a sidewall section; and

FIG. 17 is a detail view of the sidewall section shown in FIG. 16.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, and in particular FIGS. 1 and 2, there is shown a container system, generally designed 20. The container 20 includes a pallet 22, serving as a base, a sidewall 24 and a cover 26. Retaining bands or straps 28 wrap around the cover 26, sidewall 24 and pallet 22 to retain the elements together. The bands 28 extend in both lateral and longitudinal directions.

Referring now to FIGS. 3 and 4, the top cover 26 includes an outer lip 36 configured for extending around the sidewall 24 when assembled. The upper surface of the cover 26 includes banding recesses 30 and 32. Longitudinal recesses 30 extend across the top cover to receive the bands 28 as shown in FIGS. 1 and 2, while the lateral recesses 32 extend substantially perpendicular to the recesses 30 and receive the bands 28 extending laterally around the container assembly 20. In addition, the cover 26 includes nesting portions 34 forming spaced apart recesses along opposed edges of the cover 26 and are aligned to receive the bottom legs of the pallet base where the containers 20 are stacked, as explained hereinafter. As shown in FIG. 4, the underside of the cover 26 includes dimples 76 providing strength while maintaining light weight. The outer lip 36 defines a channel 38 configured for receiving the top edge of the sidewall 24.

Referring to FIGS. 5 and 8, the sidewall 24 includes four planar face portions 40 forming a generally rectangular vertically extending structure with an open top and bottom. The sidewall 24 is made of two sections in the embodiment shown with the sections 24A and 24B joined together. As shown most clearly in FIG. 16, each of the sidewall sections 24A and 24B have complementary extruded aluminum connectors 50A and 50B extending vertically at the abutting edges. Connector 50B has a planar portion that overlaps connector 50A. As shown in FIG. 17, magnets 46 provide an attraction between the two sections 24A and 24B at complementary attachment recesses 48. When joined, the sections 24A and 24B form the sidewall 24 having an open generally rectangular top profile as shown most clearly in FIG. 8. In an alternate embodiment, the sidewall may be a continuous sidewall rather than being made in two sections. In the embodiment shown, the sidewall 24 includes angled or rounded corner portions 52 at each of the four corners of the generally rectangular structure. The corner portion 52 may be reinforced and provides a short transition between the generally planar face portions 40. However, the corner portions still fit within the complementary channel 38 of the cover 36. Moreover, as shown in FIG. 6, the bottom of each corner below the edges of the planar faces 40 and the corner portion 52 include a notch 54. The notch 54 is configured for aligning with and extending over a small portion of the corner of the pallet deck and a raised portion in a sidewall receiving channel, as explained hereinafter. The sidewall 24 may be made of a substantially clear material that allows the contents to be viewed from an exterior of the container 20. The see through sidewall may be made from a corrugated polycarbonate or other lightweight high-strength material that provides for viewing the contents from outside of the container 20.

As shown in FIG. 8 and in greater detail in FIG. 7, the sidewall 24 is made of a high strength corrugated plastic material in the embodiment shown. The sidewall includes generally extending flutes 42. Some of the flutes 42 include reinforcing rods 44 that extend the length of the sidewall and provide reinforcement and greater strength while maintaining light weight. Various configurations may be used, such as shown in U.S. Pat. No. 7,163,122 to Elder, herein incorporated in its entirety by reference.

Referring now to FIG. 9, there is shown a second embodiment of a sidewall 24. The sidewall 24 of FIG. 9 is generally similar to the embodiment shown in FIGS. 5-8. However, the sidewall includes a double wall construction including an outer wall 56. The outer wall 56 is also made of a corrugated plastic material with flutes 42 and reinforcing rods 44, as shown in FIG. 7. However, in the embodiment shown in FIG. 9, the flutes 42 and reinforcing rods 44 of the outer wall 56 extend horizontally rather than vertically as with the inner wall. In this manner, greater strength is achieved while maintaining a substantially light weight sidewall. Strength and reinforcement are therefore obtained in both horizontal and vertical direction. It can be appreciated that other sidewall configurations including doors, windows and other accessories may also be utilized that fit with the pallet base 22 and the cover 26.

Referring to FIGS. 10-14, a pallet type base 22 includes a deck 60 and legs 62 extending downward from below the deck 60. In the embodiment shown, the pallet 22 includes six legs with three legs generally evenly spaced along opposed ends of the deck 60. The legs 62 have a generally rectangular configuration and a hollow center that maintains light weight. Moreover, the bottom of the legs 62 are configured for inserting into the complementary recesses 34 formed in the top surface of the cover 36. This configuration provides a slight degree of nesting and maintains the containers 20 in a stacked configuration while reducing the likelihood that stacked containers 20 slide relative to one another. The deck 60 may include smooth planar surface or a non-skid surface with raised elements protruding slightly upward from the deck 60, depending upon the application. The pallet 22 is a molded plastic element that may have reinforcing structures molded within the pallet 22 for added strength, as explained hereinafter. The pallet 22 includes an outer lip 64 and a channel 66 formed around the planar portion 62. Raised portions 68 extend upward near each corner of the pallet 22. The raised portions 68 are configured for extending into the complementary notches 54 shown in FIG. 6 when the container 20 is assembled. As shown in FIGS. 12-14, the raised protrusions 68 extend across the channel 66 and are also aligned with the notches 54. This provides for receiving the lower edge of the sidewall 24 so that the sidewall extends into the channel 66 while also providing strength and maintaining alignment.

As shown in FIGS. 13 and 14, the pallet 22 also receives reinforcing elements 86 that extends the length of the pallet 22. The reinforcing elements 86 are molded into the pallet 22 and two of the reinforcing elements 86 are covered by the raised protrusions 68 that extend upward into the channel 66. In addition to providing alignment for the sidewall 24, the protrusions 68 and reinforcing elements 86 provide for reinforcement running the entire length of the pallet 22 rather than stopping short of the channel 66. In this manner, greater support and structural integrity is provided to the pallet 22.

Referring now to FIG. 11, the underside of the pallet is molded to include features that improve performance. Dimples or kiss offs 76 provide added strength while maintaining a lightweight configuration. The dimples 76 may extend upward to support the underside of the deck 60. The dimples 76 are generally molded into the underside of the pallet deck 60 in a spaced apart configuration that provides added strength. The underside of the pallet deck 60 also includes handles 80 molded to improve handling of the pallet and maintain safety for the workers.

The pallet 22 includes banding recesses including longitudinally extending recesses 70 and laterally extending recesses 72. Each of the recesses 70 and 72 includes an angled portion 74 proximate the edge of the pallet 22 to provide for an improved transition and greater alignment of the bands 28. As shown in FIGS. 11 and 13, the recesses 70 and 72 extend the length and width of the pallet and provide for receiving the bands 28 when assembled and maintaining the bands up above the lower surface of the underside of the deck 60. It can be appreciated that the spaced apart legs 62 provide for insertion of pallet jacks and forklift tines to lift and move the pallet 24 and the container 20. However, the bands 28 are raised upward and are maintained at a position spaced apart from the tines of the pallet jacks and forklifts so that the bands 28 are not accidentally damaged, torn or misaligned due to inadvertent contact by a tine of a pallet jack or forklift.

It can be seen that the container 20 is easily assembled as the sidewall portions are simply aligned and attached together with magnets 46 and then inserted so that the bottom of the sidewall 24 extends into the complementary channel 66 of the pallet 22 and is further retained together by the channel 66. The notches 54 extend over the corners of the deck 60 and the raised portions 68. The container 20 is then loaded with articles with the pallet 22 and sidewall 24 providing sufficient support and retention. The cover 26 is then placed over the upper edge of the sidewall 24 with the top edge of the sidewall extending into the channel 38 formed in the underside of the cover 26. The lateral bands or straps 28 are wrapped around the container and positioned in the recesses 32 and 72. The longitudinal bands or straps 28 are wrapped around the container 20 in the longitudinal recesses 30 and 70. The assembled container 20 is able to hold dense, heavy loads while providing light weight and easy handling and maintains the elements 22, 24 and 26 in proper secure alignment.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. A container, comprising: a pallet base including a rectangular deck, a plurality of support portions extending downward from an underside of the deck, a channel extending into an upper surface of the deck and proximate edges of the deck; a sidewall section defining a corrugated rectangular wall having four continuous sides and setting into the channel in the pallet; a cover fitting over the sidewall section; and alignment means formed in the channel and complementary alignment means in the bottom of the sidewall for aligning the sidewall with the pallet base.
 2. A container according to claim 1, wherein the corrugated wall includes openings formed therein and wherein the sidewall includes at least one reinforcing member inserting into at least one opening.
 3. A container according to claim 1, wherein the cover defines a channel for receiving an upper edge of the sidewall.
 4. A container according to claim 1, wherein the channel includes raised portions extending upward in the channel and wherein the sidewall includes complementary notches receiving the raised portions.
 5. A container according to claim 1, wherein the pallet base comprises strap receiving portions formed in an underside of the pallet base.
 6. A container according to claim 5, wherein the strap receiving portions intersect on the underside of the pallet base.
 7. A container according to claim 5, wherein the strap receiving portions are molded into the underside of the pallet base.
 8. A container according to claim 6, wherein the strap receiving portions are molded into the underside of the pallet base.
 9. A container according to claim 1, wherein the pallet base comprises strap receiving portions formed in an underside of the pallet base and the cover comprises strap receiving portions formed on a top portion of the cover.
 10. A container according to claim 9, wherein the strap receiving portions intersect on the underside of the pallet base and on the top portion of the cover.
 11. A container according to claim 9, wherein the strap receiving portions are molded into the underside of the pallet base and the top portion of the cover.
 12. A container according to claim 9, wherein the strap receiving portions are molded into the underside of the pallet base and the top portion of the cover.
 13. A container according to claim 5, wherein the strap receiving portions comprise molded recesses.
 14. A container according to claim 9, wherein the strap receiving portions comprise molded recesses.
 15. A container according to claim 1, wherein the channel includes raised portions spaced apart in the channel and wherein the sidewall includes complementary notches aligned with the raised portions.
 16. A container according to claim 1, wherein the pallet base comprises reinforcing members molded within the pallet base and extending through the channel.
 17. A container according to claim 15, wherein the pallet base comprises spaced apart reinforcing members molded within the pallet base and extending through the spaced apart raised portions in the channel.
 18. A container according to claim 1, wherein the sidewall comprises a see through material.
 19. A container according to claim 18, wherein the sidewall comprises a corrugated polycarbonate.
 20. A pallet comprising: A base including a rectangular deck with a channel extending into an upper surface of the deck and proximate the edges of the deck; a plurality of support portions extending downward from an underside of the deck, strap receiving portions formed in an underside of the deck, wherein the channel includes raised portions spaced apart in the channel.
 21. A pallet according to claim 20, wherein the strap receiving portions intersect on an underside of the pallet.
 22. A pallet according to claim 20, wherein the strap receiving portions comprise molded recesses.
 23. A pallet according to claim 22, further comprising reinforcing members molded within the pallet base and extending through the channel.
 24. A pallet according to claim 20, further comprising spaced apart reinforcing members molded within the pallet base and extending through the spaced apart raised portions in the channel.
 25. A cover for a container, the cover comprising: a cover element having a top portion and a bottom portion defining a channel configured for receiving an upper edge of a rectangular sidewall; strap receiving portions formed in the top portion of the cover.
 26. A cover for a container according to claim 25, wherein the strap receiving portions intersect on the top portion of the cover.
 27. A cover for a container according to claim 26, wherein the strap receiving portions comprise molded recesses.
 28. A sidewall for a container having a complementary base and cover, the sidewall comprising: a corrugated first wall portion; a corrugated second wall portion, each of the first and second wall portions including a first end section, a second end section, and a center section intermediate the first and second end sections and substantially perpendicular to the first and second end sections, wherein the first and second end sections are complementary so that the first end section of the first wall portion connects to the second end section of the second wall portion, and the second end section of the first wall portion connects to the first end section of the second wall portion so that the sidewall has a substantially rectangular outer periphery; wherein the sidewall includes openings formed therein and at least one reinforcing member inserting into at least one opening.
 29. A sidewall according to claim 28, wherein the sidewall defines notches formed therein at a lower edge of the sidewall.
 30. A sidewall according to claim 28, wherein the first end section comprises a vertical first edge element and the second end section comprises a vertical second edge element complementary to the first edge element.
 31. A sidewall according to claim 30, further comprising magnets mounted at the first and second edge elements.
 32. A sidewall according to claim 31, wherein the first and second edge elements comprise aluminum elements having recess formed therein receiving the magnets.
 33. A sidewall according to claim 31, wherein each of the first and second wall portions comprises a corner portion intermediate the first end section and the center section and a corner portion intermediate the second end section and the center section.
 34. A container comprising: a pallet comprising a base including a rectangular deck with a channel extending into an upper surface of the deck and proximate the edges of the deck, a plurality of support portions extending downward from an underside of the deck, strap receiving portions formed in an underside of the deck, wherein the channel includes raised portions spaced apart in the channel; a corrugated first wall portion, and a corrugated second wall portion, each of the first and second wall portions including a first end section, a second end section, and a center section intermediate the first and second end sections and substantially perpendicular to the first and second end sections, wherein the first and second end sections are complementary so that the first end section of the first wall portion connects to the second end section of the second wall portion, and the second end section of the first wall portion connects to the first end section of the second wall portion so that the sidewall has a substantially rectangular outer periphery; and wherein the sidewall includes openings formed therein and at least one reinforcing member inserting into at least one opening; wherein the first end section comprises a vertical first edge element and the second end section comprises a vertical second edge element complementary to the first edge element, a magnet mounted at recesses formed in the first and second sections; and a cover element having a top portion and a bottom portion defining a channel configured for receiving an upper edge of a rectangular sidewall, strap receiving portions formed in the top portion of the cover. 